3D Printing: What Are the Hazards?

Abstract

As the popularity of three-dimensional (3D) printers increases, more research will be conducted to evaluate the benefits and risks of this technology. Occupational health professionals should stay abreast of new recommendations to protect workers from exposure to 3D printer emissions.

Three-dimensional (3D) printing is a booming industry that has made rapid prototyping and small-scale manufacturing easier, more accessible, and affordable (University of Vermont, n.d.) and is used in aerospace, architecture, automotive, medical and dental fabrication, defense, and commercial and consumer product manufacturing industries (Ryan & Hubbard, 2016). Advantages of using 3D printers include less time from design to manufacture, material waste, and energy consumption. Three-dimensional printers are located in schools, libraries, businesses, and home offices. The 3D printing industry is expected to grow from US$3.07 billion in revenue in 2013 to an estimated US$21 billion by 2020 (3Dprinting.com, n.d.). This proliferation of 3D printers will contribute to worker exposure to various hazards.

Three-dimensional printing, also called additive manufacturing, is a “process of making three dimensional solid objects from a digital file” (3Dprinting.com, n.d., para. 1). In an additive process, successive layers of material are laid down until the object is completed. Although several methods can be used to print, the ways layers are built to create the final product differ. Some methods melt or soften material to extrude layers; other methods cure a photoreactive resin with an ultraviolet laser layer by layer (3Dprinting.com, n.d.).

Each 3D printer uses specific types of materials such as thermoplastics (e.g., acrylonitrile butadiene styrene or polylactic acid), photopolymers, phenyl phosphates, powder metals (e.g., titanium and aluminum), ceramics, and paper. Ultrafine particles (UFPs) or nanoparticles are emitted during the 3D printing process and have been associated with adverse health effects. Heating of certain thermoplastic filament can generate toxic vapors and vapors with high volatile organic compounds (VOCs; 3Dprinting.com, n.d.; University of Vermont, n.d.). Excessive exposure to VOCs can lead to eye, nose, and throat irritations; headache; loss of coordination; and nausea. Biological materials (i.e., cells for engineered-tissue generation) can be printed causing potential exposure to aerosols generated in the process. Other hazards are overall safety related to 3D printing equipment, high power voltage, multiple moving parts, hot surfaces, indoor air quality, and static electricity.

Due to the capability of 3D printers to generate potentially harmful exposures, workplaces should establish policies and a written standard operating procedure to address health and safety concerns. Occupational health nurses should collaborate with members of the occupational health team to provide input for review and approval of 3D printer purchases. Key information to consider are the type of 3D printer, type of print media to be used, proposed location of the printer, and number of printers that will be in each area. Ventilation requirements and exhaust capabilities must be assessed prior to 3D printer operation. “The ventilation rate for 3D printers in lab locations will be dictated by the exhaust ventilation for the fume hood and/or other local exhaust systems but must be at least 8 air changes per hour” (University of Rochester, 2016, para. 2). If possible, 3D printers should be placed in a room separated from workstations or a significant distance from workstations, in a fume hood if available.

Education of employees who work with 3D printers is essential. Workers using 3D printers should be trained in the correct and safe operation of the printer including hazard communication, materials used in the 3D printer operation, safety data sheets, use of appropriate personal protective equipment (e.g., corrosion-resistant rubber gloves, splash goggles, respiratory protection, laboratory coat, rubber apron, and face shield), and no eating or drinking in the work area. Workers must be protected from hot surfaces associated with the printers. If ultraviolet light is used in the curing process, personal protective equipment and/or shielding must be provided. Antistatic mats should be used to ground all machines. Periodic health and environmental monitoring of workers and work environment is essential. As the popularity of 3D printers increases, more research is needed to evaluate the benefits and risks of this technology. Occupational health professionals should stay abreast of new recommendations to protect workers from exposures to 3D printer emissions.